Axial fuel stage injector with multiple mixing chambers, and combustor and GT system including same

The disclosure relates generally to turbomachine combustors and, more specifically, to an axial fuel stage (AFS) injector with multiple mixing chambers, and a combustor and a gas turbine system including the same.

Gas turbine systems include a combustion section including a plurality of combustors in which fuel is combusted to create a flow of combustion gas that is converted to kinetic energy in a downstream turbine section. Conventional combustors include a head end fuel nozzle assembly for combusting fuel in a primary combustion zone and axial fuel stage (AFS) injectors for combusting fuel in a secondary combustion zone downstream of the primary combustion zone. Portions of an air supply, for example, from a compressor discharge casing, are delivered to the head end fuel nozzle assembly and the AFS injectors in various flow passages. Current AFS injectors present challenges relative to adequately mixing highly reactive fuels, like hydrogen, with air and to achieving desired low exhaust emissions and desired flame holding capability.

All aspects, examples and features mentioned below can be combined in any technically possible way.

An aspect of the disclosure includes an axial fuel stage (AFS) injector for a combustor of a gas turbine (GT) system, the AFS injector comprising: a mixing member including: a plurality of mixing chambers defined in the mixing member, each mixing chamber including an inlet and an outlet, wherein each outlet is configured to be in fluid communication with a combustion liner of the combustor, and a set of fuel injectors defined in a side wall of each mixing chamber; a high-pressure (HP) air injection member defining a set of HP air jets spaced from the inlet of each mixing chamber; and a fuel plenum defined in the mixing member, the fuel plenum configured to deliver fuel from a fuel source to each set of fuel injectors, wherein each set of HP air jets is configured to direct a HP air from a HP air source into the inlet of a respective mixing chamber where fuel is injected by the set of fuel injectors.

Another aspect of the disclosure includes any of the preceding aspects, and at least one of the plurality of mixing chambers is angled at an obtuse angle relative to an axis of the combustion liner.

Another aspect of the disclosure includes any of the preceding aspects, and the set of HP air jets spaced from the inlet of each mixing chamber are configured to direct the HP air flow into a respective mixing chamber at an angle identical to an angle of the respective mixing chamber.

Another aspect of the disclosure includes any of the preceding aspects, and the fuel plenum is defined in the mixing member.

Another aspect of the disclosure includes any of the preceding aspects, and each set of fuel injectors includes a first set of fuel injectors spaced axially from a second set of fuel injectors in a respective mixing chamber of the plurality of mixing chambers.

Another aspect of the disclosure includes any of the preceding aspects, and the fuel plenum extends within an upstream side wall of each of the plurality of mixing chambers.

Another aspect of the disclosure includes any of the preceding aspects, and each set of fuel injectors is closer to the inlet than the outlet of a respective mixing chamber of the plurality of mixing chambers.

Another aspect of the disclosure includes any of the preceding aspects, and each mixing chamber of the plurality of mixing chambers has a cylindrical shape.

Another aspect of the disclosure includes any of the preceding aspects, and the plurality of mixing chambers are arranged in two rows of eight mixing chambers.

Another aspect of the disclosure includes any of the preceding aspects, and each set of HP air jets includes three HP air jets.

Another aspect of the disclosure includes any of the preceding aspects, and each HP air jet has a circular cross-sectional shape.

Another aspect of the disclosure includes any of the preceding aspects, and the plurality of mixing chambers are each angled relative to a radial direction from an axis of the combustion liner.

Another aspect of the disclosure includes any of the preceding aspects, and the mixing member and the HP air injection member each include a mounting element configured to receive a fastener to couple the mixing member and the HP air injection member to a combustion liner.

Another aspect of the disclosure includes any of the preceding aspects, and each set of HP air jets is configured to draw a low pressure (LP) air from a LP air source to direct the LP air with the HP air into the inlet of a respective mixing chamber, the HP air source is in direct fluid communication with a compressor discharge of the GT system, and the LP air source is in fluid communication with a cooling passage defined along at least a portion of the combustion liner.

Another aspect of the disclosure includes a combustor for a gas turbine system, the combustor comprising: a combustor body including a combustion liner; and a plurality of axial fuel stage (AFS) injectors directed into the combustion liner, each AFS injector including: a mixing member including: a plurality of mixing chambers defined in the mixing member, each mixing chamber including an inlet and an outlet, wherein each outlet is configured to be in fluid communication with a combustion liner of the combustor, and a set of fuel injectors defined in a side wall of each mixing chamber; a high-pressure (HP) air injection member defining a set of HP air jets spaced from the inlet of each mixing chamber; and a fuel plenum defined in the mixing member, the fuel plenum configured to deliver fuel from a fuel source to each set of fuel injectors, wherein each set of HP air jets is configured to direct a HP air from a HP air source into the inlet of a respective mixing chamber where fuel is injected by the set of fuel injectors.

Another aspect of the disclosure includes any of the preceding aspects, and at least one of the plurality of mixing chambers is angled at an obtuse angle relative to an axis of the combustion liner.

Another aspect of the disclosure includes any of the preceding aspects, and the set of HP air jets spaced from the inlet of each mixing member are configured to direct the HP air flow into a respective mixing chamber at an angle identical to an angle of the respective mixing chamber.

Another aspect of the disclosure includes a gas turbine (GT) system, comprising: a compressor section; a combustion section operatively coupled to the compressor section; and a turbine section operatively coupled to the combustion section, wherein the combustion section includes at least one combustor including: a combustor body including a combustion liner; a head end fuel nozzle assembly at a forward end of the combustor body; a plurality of axial fuel stage (AFS) injectors directed into the combustor body downstream of the head end fuel nozzle assembly, each AFS injector including: a mixing member including: a plurality of mixing chambers defined in the mixing member, each mixing chamber including an inlet and an outlet, wherein each outlet is configured to be in fluid communication with a combustion liner of the combustor, and a set of fuel injectors defined in a side wall of each mixing chamber; a high-pressure (HP) air injection member defining a set of HP air jets spaced from the inlet of each mixing chamber; and a fuel plenum defined in the mixing member, the fuel plenum configured to deliver fuel from a fuel source to each set of fuel injectors, wherein each set of HP air jets is configured to direct a HP air from a HP air source into the inlet of a respective mixing chamber where fuel is injected by the set of fuel injectors.

Another aspect of the disclosure includes any of the preceding aspects, and the plurality of mixing chambers are each angled at an obtuse angle relative to an axis of the combustion liner except at least one mixing chamber at a downstream-most axial location along the combustion liner.

Another aspect of the disclosure includes any of the preceding aspects, and the set of HP air jets spaced from the inlet of each mixing chamber are configured to direct the HP air flow into a respective mixing chamber at an angle identical to an angle of the respective mixing chamber.

Two or more aspects described in this disclosure, including those described in this summary section, may be combined to form implementations not specifically described herein. That is, all embodiments described herein can be combined with each other.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, objects and advantages will be apparent from the description and drawings, and from the claims.

It is noted that the drawings of the disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the disclosure and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering represents like elements between the drawings.

As an initial matter, in order to clearly describe the current technology, it will become necessary to select certain terminology when referring to and describing relevant machine components within the illustrative application of a turbomachine combustor and axial fuel stage (AFS) injector. When doing this, if possible, common industry terminology will be used and employed in a manner consistent with its accepted meaning. Unless otherwise stated, such terminology should be given a broad interpretation consistent with the context of the present application and the scope of the appended claims. Those of ordinary skill in the art will appreciate that often a particular component may be referred to using several different or overlapping terms. What may be described herein as being a single part may include and be referenced in another context as consisting of multiple components. Alternatively, what may be described herein as including multiple components may be referred to elsewhere as a single part.

In addition, several descriptive terms may be used regularly herein, and it should prove helpful to define these terms at the onset of this section. These terms and their definitions, unless stated otherwise, are as follows. As used herein, “downstream” and “upstream” are terms that indicate a direction relative to the flow of a fluid, such as the working fluid through a combustor of the turbomachine or, for example, the flow of air through the combustor or AFS injector, or coolant through one of the turbomachine's component systems. The term “downstream” corresponds to the direction of flow of the fluid, and the term “upstream” refers to the direction opposite to the flow. The terms “forward” and “aft,” without any further specificity, refer to directions, with “forward” referring to the front or compressor end of the turbomachine or combustor, and “aft” referring to the rearward or turbine end of the turbomachine or combustor.

The term “axial” refers to movement or position parallel to an axis, e.g., an axis of a combustor, a mixing chamber of the AFS injector, or turbomachine. The term “radial” refers to movement or position perpendicular to an axis, e.g., an axis of a combustor or a turbomachine. In cases such as this, if a first component resides closer to the axis than a second component, it will be stated herein that the first component is “radially inward” or “inboard” of the second component. If, on the other hand, the first component resides further from the axis than the second component, it may be stated herein that the first component is “radially outward” or “outboard” of the second component. Finally, the term “circumferential” refers to movement or position around an axis, e.g., a circumferential interior surface of a combustor body or a circumferential interior of casing extending about a combustor. As indicated above and depending on context, it will be appreciated that such terms may be applied in relation to the axis of the combustor or the axis of the turbomachine.

In addition, several descriptive terms may be used regularly herein, as described below. The terms “first,” “second,” and “third,” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. “Optional” or “optionally” means that the subsequently described event may or may not occur or that the subsequently described feature may or may not be present and that the description includes instances where the event occurs, or the feature is present and instances where the event does not occur, or the feature is not present.

Where an element or layer is referred to as being “on,” “engaged to,” “connected to,” “coupled to,” or “mounted to” another element or layer, it may be directly on, engaged, connected, coupled, or mounted to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. The verb forms of “couple” and “mount” may be used interchangeably herein.

Embodiments of the disclosure provide an axial fuel stage (AFS) injector for a combustor, the combustor and a gas turbine (GT) system including the same. The AFS injector includes a mixing member including a plurality of mixing chambers in fluid communication with a combustion liner of a combustor, and a set of fuel injectors defined in a side wall of each mixing chamber. A high-pressure (HP) air injection member defines a set of HP air jets spaced from the inlet of each mixing chamber. A fuel plenum is defined in the mixing member to deliver fuel from a fuel source to each set of fuel injectors. Each set of the HP air jets is configured to direct a HP air from a HP air source and, optionally, to draw a low-pressure (LP) air from a LP air source to direct the LP air with the HP air, into the inlet of the respective mixing chamber where fuel is injected. The mixing chambers direct the air-fuel mixture into the combustion liner for combustion in a secondary combustion zone thereof. The AFS injector may be additively manufactured to include a plurality of parallel, sintered metal layers.

In some embodiments, the AFS injector mixes two sources of air, one being high-pressure air, e.g., from a compressor discharge, and the other a low-pressure air, e.g., post-impingement cooling air or other lower pressure air than the high-pressure air, to reduce overall system pressure loss and to use air more efficiently in the combustor. The AFS injector can rapidly premix the two air sources with, for example, highly reactive fuels, like hydrogen, to achieve low emissions, e.g., of nitrous oxide (NOx), and an acceptable flame holding capability.

In each embodiment, the AFS injector achieves high mixedness of fuel and air, reduces flow-pressure loss, and prevents fuel from entering any low velocity air flow zones. Additionally, the AFS injector is packaged in a relatively small geometry, allowing it to be assembled onto the combustion liner of a combustor body, and the combustor body installed into the GT system through the relatively small opening in a compressor discharge casing.

shows a functional block diagram of an illustrative gas turbine (GT) systemthat may incorporate various embodiments of a combustorand axial fuel stage (AFS) injectorsof the present disclosure. As shown, GT systemgenerally includes an inlet sectionthat may include a series of filters, cooling coils, moisture separators, and/or other devices to purify and otherwise condition a working fluid (e.g., air)entering GT system. Working fluid, i.e., air, flows to a compressorin a compressor sectionthat progressively imparts kinetic energy to working fluidto produce a compressed, high-pressure (HP) air(hereafter “HP air” or “compressed air”) at a highly energized state. HP airis typically mixed with a fuelA and/orB from a fuel sourceto form a combustible mixture within at least one combustorin a combustion sectionthat is operatively coupled to compressor section. The combustible mixture is burned to produce combustion gaseshaving a high temperature and pressure.

Combustion gasesflow through a turbineof a turbine sectionoperatively coupled to combustion sectionto produce work. For example, turbinemay be connected to a shaftso that rotation of turbinedrives compressorto produce HP air. Alternately, or in addition, shaftmay connect turbineto another load, such as a generatorfor producing electricity. Exhaust gasesfrom turbineflow through an exhaust sectionthat connects turbineto an exhaust stackdownstream from turbine. Exhaust sectionmay include, for example, a heat recovery steam generator (not shown) for cleaning and extracting additional heat from exhaust gasesbefore their release to the environment. Where more than one combustoris used, they may be circumferentially spaced around a turbine inletof turbine.

In one embodiment, GT systemmay include any engine model such as those commercially available from GE Vernova of Cambridge, MA. The present disclosure is not limited to operability with any one particular GT system and may be implemented in connection with other engines including, for example, any HA, F, B, LM, GT, TM and E-class engine models of GE Vernova, and engine models of other companies. Furthermore, the present disclosure is not limited to implementation with any particular turbomachine, and may be applicable to, for example, steam turbines, jet engines, compressors, turbofans, etc.

A combustorusable within GT systemwill now be described.shows a cross-sectional side view of combustorpositioned within GT system. As will be further described herein, combustormay include one or more axial fuel stage (AFS) injectorsaccording to embodiments of the disclosure.

As shown in, combustoris at least partially surrounded by an outer casingsuch as a compressor discharge casing and/or a turbine casing. An interior of outer casingis in fluid communication with a compressor dischargeof compressorand creates an HP air source. That is, HP air sourceincludes HP airfrom compressor discharge of compressor. HP sourceis in direct fluid communication with a compressor dischargeof GT system. However, HP air sourcemay be any supply of HP aircapable of flowing into any variety of opening or flow passage in combustorto cool parts and/or for combustion, i.e., in AFS injectors.

As shown in, combustorfor GT systemincludes a combustor body. Combustor bodymay be made using any now known or later developed techniques. For example, combustor bodymay be additively manufactured. Combustor bodymay include a combustion liner, which may include, for example, a cylindrical portionand a tapered transition portion. Combustion linermay have an axis A, the direction of which may vary slightly depending on axial location within the curved combustion liner. Tapered transition portionis at an aft end (right side as shown in) of cylindrical portion. As understood in the field, tapered transition portiontransitions the hot gas path (HGP) from the circular cross-section of the liner's cylindrical portionto a more arcuate cross-section for mating with turbine inletof turbine. Combustormay also include an aft frameat an aft end (right side in) of tapered transition portion.

Combustion linermay contain and convey combustion gasesto turbine section(). More particularly, combustion linerdefines a combustion chamber, i.e., in a hot gas path (HGP), where combustion occurs. Combustion linermay have tapered transition portionthat is separate from cylindrical portion, as in many conventional combustion systems. Alternately, as shown in, combustion linermay have a unified body (or “unibody”) construction, in which cylindrical portionand tapered transition portionare integrated with one another, i.e., as part of an additively manufactured one-piece member. Thus, any discussion of combustion linerherein is intended to encompass conventional combustion systems having a separate cylindrical, tapered transition portions, and/or those combustion systems having a unibody liner.

Combustor bodyalso includes an air flow passagedefined at least partially by cylindrical portionof combustion liner. As will be described herein, air flow passageis configured to deliver air (e.g., HP airA from HP air source) to a head end fuel nozzle assembly(hereinafter “head end assembly” for brevity) of combustorat a forward end (left end in) of combustion liner. That is, air flow passageis sized, shaped and/or arranged to deliver air, such as HP airA from HP air source, to head end assemblyof combustor. Air flow passagemay be defined wholly within cylindrical portion, or air flow passagemay be provided between cylindrical portionand a flow sleevespaced along at least a portion of an exterior surface of cylindrical portion. Air flow passagehas an open end, or air flow opening(s), proximate to head end assemblythrough which HP airA from HP air sourceenters. Here, HP airA from HP air sourcemay be pulled directly from compressor discharge, i.e., without any other use of the air other than coincidental convection cooling of combustor body.

An annular partitiondisposed between cylindrical portionand flow sleeveseparates a forward portion of air flow passagefrom an aft portion of air flow passage. The axial position of annular partitionis approximately aligned with a cap assembly, discussed below, such that the forward portion of air flow passageis radially outward of head end assembly(rather than combustion chamber) and, therefore, requires less cooling. Aftward of annular partition, flow sleevemay include a plurality of impingement holes(as shown in outer sleeve), which permit HP airB to flow into air flow passage. As a result of passing through impingement holes, HP airB experiences a pressure drop and becomes LP air, which flows through air flow passagetoward and/or into AFS injector(s), as discussed further herein.

Head end assemblygenerally includes at least one axially extending fuel nozzlethat extends downstream from an end coverand a cap assembly, which extends radially and axially within outer casingdownstream from end coverand which defines the forward boundary of combustion chamber. Head end assemblymay include any now known or later developed axially extending fuel nozzlesfor delivering first fuelA to a primary combustion zonefrom axially extending fuel nozzles. In certain embodiments, axially extending fuel nozzle(s)of head end assemblyextend at least partially through cap assemblyto provide a combustible mixture of fuelA and HP airA to primary combustion zone.

Combustor bodyalso includes an axial fuel stage (AFS) injector opening or seatdirected into combustion linerdownstream of head end assembly. Opening or seatextends through a wall of combustion liner. One or more AFS injector openings or seats(hereafter “openings”) can be provided and are configured to have an AFS injectormounted thereto and receive HP airB from HP air source, possibly among other air flows as will be described herein. Each AFS injector openingmay include any structure operable to allow an AFS injectorto be mounted thereto, e.g., threaded fasteners, bolt holes, weld area, etc. As illustrated, combustorand combustor bodymay include a plurality of circumferentially spaced AFS injector openingsand corresponding AFS injectors. Any number of AFS injectorscan be used.

As will be described, in certain embodiments, AFS injector(s)are also configured to receive (draw in) a low-pressure (LP) airfrom a low-pressure (LP) air source, e.g., cooling passage, and direct it into combustion linerwith fuelB. FuelB may be delivered from fuel sourceusing any form of fuel line(s). FuelA,B may be any now known or later developed combustorfuels, such as but not limited to fuel oil, natural gas, hydrogen, and/or blends thereof. FuelsA,B may be the same or different.

In some embodiments, LP aircan be delivered to AFS injector(s)in a variety of ways from LP air source. In certain embodiments, LP airoriginates from HP air sourcebut is used for cooling before use in AFS injector(s). In one example, combustor bodyfurther includes a cooling passage(s)at least partially defined by tapered transition portionthat provides LP air source. Cooling passage(s)may also be in fluid communication with other cooling passages (not shown) in combustor. In any event, LP airof LP air sourcemay be used for cooling one or more hot parts of combustor. More particularly, LP airof LP air sourcepasses through cooling passage(s), which as noted is at least partially defined by tapered transition portion, after being pulled from compressor discharge.

In one example, cooling passage(s)may be formed by a flow sleeveor within tapered transition portion. Where desired, impingement cooling holesmay be provided in flow sleevesurrounding tapered transition portionto allow HP airto enter from HP air sourceand become LP air. In this regard, LP air sourceincludes cooling passage(s)defined along at least a portion of combustion liner, e.g., tapered transition portion. Further, cooling passage(s)may optionally be downstream of an impingement cooling member (portionwith impingement cooling holesin outer sleeve thereof or sleeve around portionwith holestherein) which is in turn in direct fluid communication with compressor dischargeof GT system, i.e., HP air source. It is noted that hot part(s)may include any part of combustorrequiring cooling, and LP airmay be directed to enter the cooling passage(s) in any manner desired, and cooling passage(s)may be defined in or along (other) hot part(s) of combustorother than tapered transition portion, e.g., aft frame. In any event, cooling passage(s)is/are between AFS injector(s)and HP air sourcewith the cooling passage(s), in some embodiments, being configured to deliver LP airof LP air sourceto AFS injector(s). LP airfrom LP air sourcemay also be referred to herein as a “post-cooling” or “post-impingement air” since it is used to provide significant cooling of parts of combustor. While LP airhas been described herein as being post-cooling air, it is emphasized that it can be any air having a lower pressure than HP airand LP air sourcecan be other than described herein.

As noted, combustorincludes at least one axial fuel stage (AFS) injectordirected into combustor body, i.e., combustion liner. As noted, AFS injectormay include a plurality of AFS injectorscircumferentially spaced around combustor body. Each AFS injectorextends radially through combustion linerdownstream from head end assembly, i.e., downstream from axially extending fuel nozzle(s). As will be further described, AFS injectorsare configured to receive HP airB of HP air sourceand, optionally, to draw in LP airfrom LP air source. In particular embodiments, LP airof LP air sourcemay be routed to AFS injector(s), e.g., in cooling passage(s), to combine with HP airB and second fuelB for combustion in a secondary combustion zonethat is downstream from primary combustion zone.